GESTRA NRR 2-52 Installation & Operating Manual Download Page 68

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GESTRA AG

Münchener Strasse 77
28215 Bremen
Germany
Phone +49 421 3503-0
Fax

+49 421 3503-393

e-mail [email protected]
Web www.gestra.com

850646-00/03-2021cm (809102-00) · GESTRA AG · Bremen · Printed in Germany

You can find our authorised agents around the world at:

www.gestra.com

Summary of Contents for NRR 2-52

Page 1: ...Installation Operating Manual E N English Level Controller NRR Visual Display and Operating Unit URB NRR 2 52 NRR 2 53 URB 55 850646 00 ...

Page 2: ...ity 12 Function 13 Possible combinations of functions and equipment 13 Technical data NRR 2 52 NRR 2 53 15 Technical data URB 55 17 Factory settings NRR 2 52 NRR 2 53 19 NRR 2 52 19 NRR 2 53 19 NRS 2 52 NRR 2 53 19 Factory settings URB 55 20 Name plate Marking NRR 2 52 21 Name plate Marking NRR 2 53 22 Name plate Marking URB 55 23 Functional elements and dimensions NRR 2 52 NRR 2 53 24 Installing ...

Page 3: ...55 33 Connecting the SPECTORmodul system 33 Changing the equipment settings 34 Setting the measuring range 36 Setting the measuring range for the NRGT 26 x level transmitter 36 Status display of the NRR 2 52 NRR 2 53 37 Visual display and operating unit URB 55 38 Switching on the supply voltage 38 Operation and navigation 39 User interface example 39 Colour coding of input and status fields 39 Aut...

Page 4: ...ting the level controller for 3 component control 60 System malfunctions URB 55 61 Display of system malfunctions in the alarm and error list using fault codes 61 Common faults and issues during use of the URB 55 62 System malfunctions NRR 2 52 NRR 2 53 63 Causes 63 Before starting systematic troubleshooting check the installation and configuration 63 What to do in the event of system malfunctions...

Page 5: ...ls on our website http www gestra com documents brochures html Copyright All rights reserved Any misuse particularly reproduction and dissemination to third parties is not permit ted The General Terms Conditions of GESTRA AG apply Scope of delivery Product package NRR 2 5x 1 x Level NRR 2 52 or NRR 2 53 URB 55 1 x visual display and operating unit URB 55 4 x retaining clips 1 x power supply connec...

Page 6: ...ad this Manual in full and follow all instructions Please also read the instructions for use of any accessories The Installation Operating Manual is part of the product package Keep it in an easily accessible location Availability of this Installation Operating Manual Make sure this Installation Operating Manual is always available to the operator If you pass on or sell the equipment to a third pa...

Page 7: ...situation that results in death or serious injury WARNING Warning of a dangerous situation that may possibly result in death or serious injury CAUTION CAUTION Warning of a situation that may result in minor or moderate injury ATTENTION ATTENTION Warning of a situation that results in damage to property or the environment ...

Page 8: ...ing positive or draining negative Pb proportional band The proportional band enables the controller amplification to be adapted to suit the controlled system For further information see page 59 guide to setting control parameters Ti reset time The integral element ensures that control deviations can be fully corrected with no remaining deviation For further information see page 59 guide to setting...

Page 9: ...n a control cabinet door or switch panel It may only be used when correctly installed If you are using a URB 50 please pay attention to the information in Installation Operating Manual NRR2 52 NRR2 53 URB50 Overview of possible unit combinations Level controller Level electrode Visual display and operating unit NRR 2 52 NRR 2 53 NRG 21 xx URB 55 NRG 26 21 NRGT 26 x Fig 1 Key to Fig 1 NRR level con...

Page 10: ... restrict access and control to individ ual products and networks Applicable directives and standards NRR 2 52 NRR 2 53 The NRR 2 52 NRR 2 53 level controller has been tested and approved for use in the scope governed by the following directives and standards Directives Directive 2014 35 EU Low Voltage Directive Directive 2014 30 EU EMC Directive Directive 2011 65 EU RoHS Directive Standards EN 60...

Page 11: ...ironments EN 61000 4 29 2000 Electromagnetic compatibility EMC Part 4 29 Testing and measurement techniques Voltage dips short interruptions and voltage variations on d c input power port immunity tests EN 61000 6 4 2007 A1 2011 Electromagnetic compatibility EMC Part 6 4 Generic standards Emission standard for industrial environments EN 60945 2002 Maritime navigation and radiocommunication equipme...

Page 12: ...expected it may be faulty Perform failure analysis Only replace faulty equipment with identical equipment from GESTRA AG Required personnel qualifications Activity Personnel Integration in control system Specialist staff Plant designer Installation electrical connection bringing into service Specialist staff Electrician installer Operation Boiler service technician Staff trained by the plant opera...

Page 13: ... xx level electrodes with standardisation of the measuring range l l Evaluating the current signal of a connected NRGT 26 x level transmitter l l 3 position stepping controller with proportional plus integral control PI controller and actuation of an electrically operated control valve l Continuous controller as a PI controller for actuating an electro pneumatic control valve l Continuous controll...

Page 14: ...ition bar chart and in l Measuring range standardisation when an NRG 2 level electrode is connected l Display setting control parameters l Standardising and evaluating current inputs for steam and feedwater flowrate 3 component control optional l Trend log l Display and list of faults alarms and warnings l Test of MIN MAX output relays l Manual automatic mode l Password protection l Level and cond...

Page 15: ... of NRR 2 52 1 x MIN 1 x MAX alarm 2 x volt free relay contacts changeover relays Maximum switching current 8 A at 250 V AC 30 V DC cos ϕ 1 Outputs of NRR 2 53 2 x MIN 2 x MAX alarm 4 x volt free relay contacts changeover relays MIN1 MAX1 alarm Maximum switching current 8 A at 250 V AC 30 V DC cos ϕ 1 or 1 x MIN1 1 x MAX1 alarm and 2 x pump enable ON OFF MIN2 MAX2 enable pump 1 pump 2 2 x volt fre...

Page 16: ...ulated IP rating to EN 60529 Housing IP 40 Terminal strip IP 20 Electrical safety Degree of contamination 2 for installation in control cabinet with protection rating IP 54 Admissible ambient conditions Service temperature 10 C 55 C 0 C 55 C at power on Storage temperature 20 C 70 C Transport temperature 20 C 80 C 100 hours Air humidity max 95 non condensing Only switch on after a 24 hour defrosti...

Page 17: ... Resolution 800 x 480 pixels WVGA Brightness 200 Cd m2 dimmable Size field of view 110 mm x 65 mm IP rating Front IP 66 Back IP 20 Admissible ambient conditions Service temperature 0 C 60 C Storage temperature 20 C 70 C Transport temperature 20 C 70 C Air humidity 5 85 relative humidity non condensing Housing Material Front metal glass rear metal electronics housing Housing attachment with the sup...

Page 18: ... data URB 55 Weight Approx 1 kg Internal battery permanently installed non replaceable Type Lithium ion battery is charged automatically If the equipment is out of service for six months or more we recommend connecting it to the supply voltage for one day to recharge the battery ...

Page 19: ... Input wired as a voltage input for the connection of an NRG 21 or NRG 26 21 level electrode Measuring range 100 NRR 2 52 MAX switchpoint 80 MIN switchpoint 20 NRR 2 53 MAX1 switchpoint 80 MAX2 switchpoint 60 MIN2 switchpoint 40 MIN1 switchpoint 20 NRS 2 52 NRR 2 53 Set point 50 of measuring range Direction of corrective action Inlet control Proportional band Pb 20 of set point Reset time Ti 0 sec...

Page 20: ...anual 850646 00 Factory settings URB 55 The visual display and operating unit is delivered with the following factory settings PWL 1 111 Conductivity in µS cm Remote access ON Target IP 192 168 0 84 Subnet 255 255 255 0 Gateway 192 168 0 1 Modbus TCP Off ...

Page 21: ...kOhm MAX 3s M0 5A _ _ _ 24V DC GESTRA AG Münchener Str 77 28215 Bremen Made in Germany 5W 24V 20 IP40 IP20 OUT 4 20mA URB 5 Data 1 12V _ 4 20mA NRG 2 3 2 Alarm IN 1 IN xxxxxxxxxxxx 5W Betriebsanleitung beachten See installation instructions Voir instructions de montage 24V 20 NRR 2 52 IP40 IP20 Niveauregler Level Controller Régulateur de niveau TÜV WR xx xxx 17 2 22 7 27 12 16 1 21 6 26 11 18 3 23...

Page 22: ...5A MIN2 P1 MAX2 P2 MAX1 _ 24V DC GESTRA AG Münchener Str 77 28215 Bremen Made in Germany 1 4 20mA URB 5 Data 1 12V _ 4 20mA NRG 2 3 5W 24V 20 IP40 IP20 OUT2 4 20mA 2 Alarm IN 1 MIN 1 IN 5W Betriebsanleitung beachten See installation instructions Voir instructions de montage NRR 2 53 Niveauregler Level Controller Régulateur de niveau TÜV WR xx xxx 17 2 22 7 27 12 16 1 21 6 26 11 18 3 23 8 28 13 19 ...

Page 23: ...on a Flat Surface of a Type 12 4X Enclosure GESTRA AG Münchener Straße 77 28215 Bremen www gestra com URB 55 Mat Nr 393347 Mat Nr 393347 ANW Nr 307625 Type designation Mains voltage Power consumption Serial number Date of production DD WW Safety note Stock code Disposal information IP rating UL listed Admissible ambient temperature Manufacturer Fig 9 ...

Page 24: ...rews M3 D 4 pole code switch for configuring the level controller E Front membrane with status LED see page 37 F Housing G Support rail TH 35 The code switch can be accessed by disconnecting and removing the lower terminal strip Equipment settings see page 35 Fig 10 100 73 118 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 MAX 1 27 16 17 18 19 20 21 22 23 24 25 26 28 29 30 A B C F G D E ...

Page 25: ... There is a risk of electric shock during work on electrical systems Switch off the voltage to the plant before you install the equipment Check that the system is not carrying live voltage before commencing work 1 Switch off the voltage to the system or secure the surrounding equipment in the control cabinet if live so it cannot be touched 2 Carefully press the unit onto the support rail until the...

Page 26: ... 2 53 URB 55 Installation Operating Manual 850646 00 Dimensions URB 55 107 mm 147 mm 147 mm 136 mm 96 mm 8 mm 52 mm 136 mm 96 mm Required installation aperture in the control cabinet door or switch panel Fig 12 Fig 11 ...

Page 27: ...6 x 96 mm e g in a control cabinet door B 4 x fastening elements supplied C 4 x mounting holes in the equipment Fig 14 1 Cut an aperture see Fig 13 in the control cabinet door or switch panel 2 Stick the supplied gasket to the back of the display frame 3 Carefully push the URB 55 visual display and operating unit through the aperture making sure the gasket is correctly seated 4 Insert the supplied...

Page 28: ... slot for SD card with FAT32 file format for service purposes SDHC memory cards are not supported Connection for 24 V DC supply voltage pin assignment Connector Socket Fig 16 Use a SELV Separated Extra Low Voltage power supply unit for connecting the supply voltage To connect the supply voltage to the supplied 3 pole connector use a cable with a max con ductor size of 2 5 mm2 Pin assignment of the...

Page 29: ...level controller DANGER DANGER Incorrectly connecting the level controller or any associated components is a danger to system safety Connect the level controller and all associated components as shown in the wiring diagrams in Fig 18 Fig 19 of this Manual Do not use unused terminals as jumpers or support terminals ...

Page 30: ...MIN CLOSED Supply voltage fuse provided by customer M0 5A Analogue input 2 for feedwater flowrate optional Data line for URB 55 OPEN MAX Actual value output X Display of valve position potentiometer 0 1000 W OUT MIN alarm relay output Control valve actuation MAX alarm relay output 3 s 3 s Digital input alarm signal for control centre Analogue input 3 for steam flowrate optional shield NRG 21 xx NR...

Page 31: ... 14 4 20 mA Data line for URB 55 shield Supply voltage fuse provided by customer M0 5A Actual value output X Analogue output manipulated variable Yw Analogue input 2 Feedwater flowrate optional Analogue input 3 Steam flowrate optional MIN 1 MIN 2 MAX 2 MAX 1 OUT 1 OUT 2 3 s 3 s 3 s 3 s MIN 1 alarm MIN 2 alarm pump 1 MAX 2 alarm pump 2 MAX 1 alarm Digital input alarm signal for control centre Has n...

Page 32: ... the level electrode level transmitter Use a shielded multi core twisted pair control cable with a minimum conductor size of 0 5 mm2 e g LIYCY 2 x 0 5 mm2 Maximum cable length 100 m Connect the shield as shown in the wiring diagrams Route connecting cables separately from power cables Connecting the actual value output OUT1 and analogue output OUT2 4 20 mA Please note the load resistance of max 50...

Page 33: ... Fig 18 Fig 19 Wire the 9 pole D sub connector as shown in Fig 17 Connect the earthing point of the housing URB 55 to the central earthing point in the control cabinet Connect the shield just once to the central earthing point in the control cabinet Route connecting cables separately from power cables Connecting the SPECTORmodul system Using the supplied data cable 5 m connect the URB 55 to the fi...

Page 34: ...can change the input and function of the NRR 2 52 NRR 2 53 level controller at any time using code switch D see Fig 20 Make changes before installing the level controller when access is easier You will need the following tools Slotted screwdriver size 2 5 fully insulated Phillips screwdriver size 1 fully insulated Proceed as follows 1 Switch off the supply voltage to the equipment or plant 2 Unscr...

Page 35: ...ttings Code switch D sliding switch white NRR 2 52 NRR 2 53 level controller Code switch D S1 S2 S3 S4 Configuration OFF Inlet control factory setting ON Discharge control OFF Input for connecting NRG 21 xx or NRG 26 21 factory setting ON Input for connecting NRGT 26 x level transmitter Fig 20 ...

Page 36: ...value and upper bound 100 calibration value of the measuring range of the connected level electrode This will give you the neces sary active measuring range as a percentage of the boiler level You can determine these values for the connected level electrode by performing calibration To do this read the relevant information in the Installation Operating Manual of the connected NRG 21 xx or NRG 26 2...

Page 37: ...37 NRR 2 52 NRR 2 53 URB 55 Installation Operating Manual 850646 00 Status display of the NRR 2 52 NRR 2 53 Fig 21 Multicolour LED orange green red orange power up green running red malfunction ...

Page 38: ...For the level controller s the LED first lights up orange then green The home screen of the URB 55 visual display and operating unit appears If two controllers are connected to the visual display and operating unit both controllers will be shown see example If you tap one of the controller over view screens a full screen for that controller will open on the display see screenshot below If just one...

Page 39: ...indow shows operating states and actual values The icons open the associated parameter screens These icons change dynamically and are either shown or hidden depending on the current page and configuration All entries and actions e g opening setup menus and parameter screens are initiated by tapping the buttons and input fields The active screen has a grey background see above You can close smaller...

Page 40: ...g on the display for one hour the program automatically returns to the home screen If communication to the controller is disrupted the message Offline appears in the general display area Entering parameters using the virtual keypad Tapping an input field opens a numeric virtual keypad The keypad shows the old value Old and the limits Min Max Your entries must remain within these limits Function ke...

Page 41: ...tes you will be logged off again Factory set password Password 111 Recommendation for initial setup Log on using the factory setting then safeguard your system by setting your own password Disabling parameter entries after successful Scroll bar for long lists and menus You can use the scroll bar to navigate up and down long lists and menus to select the desired parameters Scroll bar login Paramete...

Page 42: ...valve mode is possible Setup settings Valve mode Only pump or valve mode is possible Home screen Controller parameters Level controller 3C controller parameters Conductivity controller Open valve Close valve Logged in with password Log off Alarm history Info Reset alarm Time Alarm number Password Alarm coming Network Alarm going Modbus TCP overview optional Reset alarm ...

Page 43: ...rate Apply entry Confirm entry Steam flowrate Switch on Inlet control Switch off Discharge control Datalog Trend Pump OFF threshold Electrode calibration Pump ON threshold Set point Stop pump in manual mode Manual mode Start pump in manual mode Max alarm switchpoint Off On Automatic Min alarm switchpoint Off On Relay test Max switchpoint Proportional band Min switchpoint Reset time Set point Valve...

Page 44: ...44 NRR 2 52 NRR 2 53 URB 55 Installation Operating Manual 850646 00 Icon Description Icon Description Pump 1 On Pump 2 On Pump 1 Off Pump 2 Off Forced pump switchover Fig 23 ...

Page 45: ...reen buttons are shown or hidden depending on the current configuration Opening the parameter screens Use the following buttons to open the controller parameter screens Switchpoints see page 52 Trend see page 54 Test Controller information see page 54 Valve control see page 56 or Pump control see page 57 Boiler level calibration see page 58 Set controller parameters see page 59 Set 3C controller p...

Page 46: ... of the alarm and error list Alarms and error messages are entered in the columns Coming Going Reset with a time stamp The most recent alarm is always shown at the top of the list Description of display The alarms are stored in the list with a code A alarm E error Coming Time at which the event occurred Going Time when the event ended Reset Date and time the event was acknowl edged and reset Optio...

Page 47: ...al 850646 00 Alarms and error messages Opening the Alarm History full list of all alarms All alarms are stored in an Alarm History There is memory capacity for 300 alarms Alarms are stored in cycles and resto red after a power failure Open the Alarm History ...

Page 48: ...the line with the URB 55 for 2 s to see the runtime and OS of the URB 55 Opening further menus System information Setting the date time Password Network settings Open Modbus TCP list optional System information Open the System Information menu and select the desired action Description of display The connected controller s are shown with their software version Press the button to update a system or...

Page 49: ...ed settings Description of display settings Time Date Tap the appropriate field and set the date and time Confirm these changes to apply them Password Open the Password menu Factory setting 111 Changing your password 1 Tap the input field 2 Enter the new password in the top line and confirm it by entering it again in the second line ...

Page 50: ...IP address is obtained via DHCP IP Address The IP address of the URB 55 Subnet mask The current subnet mask Gateway The IP address of the gateway Data exchange via Modbus TCP The URB 55 visual display and operating unit has a Modbus TCP server This enables all values to be forwarded to a higher level control system or control centre For Modbus communication switch on the connection using the TCP O...

Page 51: ...y of the URB 55 on the computer To access the URB 55 use the previously set network parameters You also need to switch on the service If Modbus communication has been switched on you can open the dynamic datapoint list The raw data from the register are shown on this screen There is a scroll bar at the side for scrolling through the data You can find the latest datapoint list on our website at htt...

Page 52: ...larm points that are too high or too low Description of bar charts X Actual value uncompensated X1 Actual value compensated 3C con troller not shown here W Set point The set point is shown in the actual value bar chart with a small arrow Yw Manipulated variable Change of colour on alarm The bar chart column turns red in the event of an alarm Icons and functions that vary depending on configuration...

Page 53: ...roller to Manual mode Here if the controller is configured as a valve controller an input field opens in which you can enter the valve position or manipulated variable If the controller is configured as a pump controller the manipulated variable is entered and the pump is switched on off Manual mode is not disabled auto matically Valve control in manual mode example Pump control in manual mode exa...

Page 54: ...Navigation Navigate forwards and backwards on the time axis using these buttons or by swiping horizontally Zoom the display in out using these buttons or using two fingers pinch gesture Close the view Trend log for a 3C controller If the controller is configured as a 3C controller the parameters are also shown as a trend Here the 3C icon see white circle above is additionally shown in the Trend bu...

Page 55: ... the relay test 3 second delay This causes actual tripping of relay contacts in the controller The relevant icons are shown in the top part of the screen depending on the configuration example The relay in the level controller remains active while you are pressing the button Actual value output X 4 20 mA Out 1 Manipulated variable output Yw Pump s 4 20 mA Out 2 Switch between valve and pump contro...

Page 56: ... The calibrated raw data is shown in both fields Raw data Indicates the current digital valve position Auto Manual Switch between automatic and manual mode If no feedback potentiometer is connected to the level controller the parameters are not displayed 1 Press the Automatic button and switch to manual mode 2 Enter 0 as the manipulated variable Yw 3 When the valve is in the CLOSED end position co...

Page 57: ...eters Pump 1 2 On Off Enable a connected pump so it is ready for operation ON threshold Set the value at which the pump turns on OFF threshold Set the value at which the pump turns off Forced switchover Set the value level at which an automatic change of pump must take place Description of bar chart The Yw bar chart shows the manipulated varia ble of the controller output 4 20 mA normalised to 100...

Page 58: ...d by entering the data in the 0 and 100 fields this function can be used to transfer level calibration values to the new controller Performing calibration The system must go to the 0 range or this range must be calibrated Calibration may be performed in any order 1 Press the Automatic button and switch to manual mode 2 0 Reduce the boiler level to 0 3 When this level is reached confirm it The raw ...

Page 59: ...ay open close continually Example Measuring range 100 200 mm from sight glass Set point SP 80 of measuring range 160 mm Proportional band Pb 20 of set point 32 mm With the measuring range and set point mentioned above the proportional band is then 16 32 mm or in the range 128 mm to 192 mm Reset time Ti higher Slow correction of deviations Responds quickly lower Fast correction of deviations the co...

Page 60: ...used in the system Open the 3C control parameter screen Description of parameters Feedwater ﬂowrate Steam ﬂowrate k Quality factor This factor assesses how much the difference steam flowrate feedwater flowrate influences the measured level When one of the parameters is selected the following window opens For each type of flowrate enter the measuring range of the connected sensors for the analogue ...

Page 61: ...ower and upper bounds of meas uring range changed round Reset measuring range E 013 Switchpoints implausible MIN MAX Reset the switchpoints E 015 Steam flowrate measuring current 4 mA Check steam flowrate current transmitter and replace if necessary Check electrical connection E 016 Steam flowrate measuring current 20 mA Check steam flowrate current transmitter and replace if necessary Check elect...

Page 62: ... URB 55 with the USB stick inserted and perform the desired action again The USB stick must have the file format FAT32 The USB stick may not be suitable for this data transfer The home screen remains blank Remedy The URB 55 is not properly connected to the data interface When two units are connected the conductivity controller does not switch Incorrect parameter display Remedy Reboot the URB 55 ...

Page 63: ...vibration interference sources etc Wiring Does the wiring conform to the wiring diagrams Do the signal lines have the correct polarity Level controller configuration Are the inputs and functions correctly set on code switch D Configuration of electrodes Are the electrodes correctly set and has the measuring range been calibrated DANGER DANGER There is a risk of electric shock during work on electr...

Page 64: ... Taking the NRR 2 52 NRR 2 53 out of service 1 Switch off the supply voltage and switch off the power to the equipment 2 Check that the equipment is not live 3 Unscrew and pull off the lower terminal strip see Fig 10 A B 4 Release the slider holder on the base of the equipment and detach the level controller from the support rail Taking the URB 55 out of service 1 Switch off the supply voltage and...

Page 65: ...r radiation GESTRA AG can accept returned products only if accompanied by a completed and signed return note and also a completed and signed declaration of decontamination The return confirmation and declaration of decontamination must be attached to the outside of the return package as processing will otherwise be impossible and the products will be returned to the sender at their expense Please ...

Page 66: ...e conformity of our equipment with European directives The current Declaration of Conformity can be found online at www gestra com or can be requested from us EU Declaration of Conformity URB 55 We hereby declare that the URB 55 visual display and operating unit conforms to the following European directives Directive 2014 30 EU EMC Directive Directive 2011 65 EU RoHS Directive Please see our Decla...

Page 67: ...67 NRR 2 52 NRR 2 53 URB 55 Installation Operating Manual 850646 00 For your notes ...

Page 68: ...5 Bremen Germany Phone 49 421 3503 0 Fax 49 421 3503 393 e mail info de gestra com Web www gestra com 850646 00 03 2021cm 809102 00 GESTRA AG Bremen Printed in Germany You can find our authorised agents around the world at www gestra com ...

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